U.SURYAPAVANRAJU 07241A03B6 S.KARTHIK07241A0337 A.V.

YESASVI07241A0324

ABSTRACT
y Thecrankshaftexperiencesacomplexloadingduetothemotionofthe

connectingrod,whichtransformstwosourcesofloadingtothecrankshaft. Themainobjectiveofthisstudywastheoptimizationoftheforgedsteel crankshaftwhichrequiresaccuratemagnitudeoftheloadingonthis componentthatconsistsofbendingandtorsion. Thesignificanceoftorsionduringacycleanditsmaximumcomparedto thetotalmagnitudeofloadingisinvestigatedtoseeifitisessentialto considertorsionduringloadingornot. Themainobjectiveofthisstudyistodeterminethemagnitudeand directionoftheloadsthatactonthebearingbetweenconnectingrodand crankshaft,whichwasthenusedintheFEAoveranentirecycle. Inthisproject,structuralanalysiswasdoneatvariousspeedstostudythe stressconcentrationsatcriticallocationsofcrankshaft.Thentheoriginal crankshaftisoptimizeforweightandgeometry Resultsfromthisstudyshowsthatoptimizedgeometrycanbeused insteadoforiginalcrankshaftreducingitssize.Hencetheoptimized crankshaftresultsinincreasedefficiency.

INTRODUCTION
y Crankshaftisalargecomponentwithacomplexgeometryintheengine,

whichconvertsthereciprocatingdisplacementofthepistontoarotary motionwithafourlinkmechanism. y Sincethecrankshaftexperiencesalargenumberofloadcyclesduringits servicelife, life fatigueperformanceanddurabilityofthiscomponenthastobe consideredinthedesignprocess. y Designdevelopmentshavealwaysbeenanimportantissueinthe crankshaftproductionindustry, industry inordertomanufacturealessexpensive componentwiththeminimumweightpossibleandproperfatiguestrength andotherfunctionalrequirements. y Theseimprovementsresultinlighterandsmallerengineswithbetterfuel efficiencyandhigherpoweroutput.

3DSOLIDMODELING
y Solidmodelingofthecrankshaftisdoneusingpro/ENGINEERasperthe y

dimensionsandspecifications. Pro/ENGINEERisstandardin3Dproductdesign,featuringindustryleading productivitytoolsthatpromotebestpracticesindesignwhileensuring compliancewithindustryandcompanystandards. Integrated,parametric,3DCAD/CAM/CAEsolutionsallowyoutodesign fasterthanever,whilemaximizinginnovationandquality,toultimately createexceptionalproducts. Acrankshaftcontainstwoormorecentrallylocatedcoaxialcylindrical ("main")journalsandoneormoreoffsetcylindricalcrankpin("rod") journals. Thecrankshaftmainjournalsrotateinasetofsupportingbearings("main bearings"),causingtheoffsetrodjournalstorotateinacircularpath aroundthemainjournalcenters.

3DSOLIDMODELOFCRANKSHAFT

STRUCTURALANALYSIS
y Structuralanalysisisaprocesstoanalyzeastructuralsysteminorderto

y y y y y y y

predicttheresponsesoftherealstructureundertheexcitationofexpected loadingandexternalenvironmentduringtheservicelifeofthestructure. Thepurposeofastructuralanalysisistoensuretheadequacyofthedesign fromtheviewpointofsafetyandserviceabilityofthestructure. Thefollowingtypesofstructuralanalysiscanbeperformed: Staticanalysis M d lanalysis Modal l i Harmonicanalysis Transientdynamicanalysis Spectrumanalysis Bucklinganalysis.

VONMISESSTRESS
y Inaelasticbodythatissubjectedtoasystemofloadsin3dimensions,a y y y y y

complex3dimensionalsystemofstressesisdeveloped.Thatis,atany point acting and i twithin ithi the th body b d there th arestresses t ti in i different diff tdirections, di ti d thedirectionsandmagnitudeofstresseschangesfrompointtopoint. TheVonmises criterionisaformulaforcalculatingwhetherthestress combinationatagivenpointwillcausefailure. Therearethreeprinciplestressesthatcanbecalculatedatanypoint, actinginx,yandzdirections. VonMises foundthat,eventhoughnoneoftheprincipalstressesexceed theyieldstressofthematerial, material itispossibleforyieldingtoresultfromthe combinationofstresses. TheVonMises criterionisaformulaforcombiningthese3stressesintoan equivalentstress,whichisthencomparedtotheyieldstressofthe material. material TheequivalentstressisoftencalledtheVonMises Stressasashorthand description.Itisnotreallyastress,butanumberthatisusedasanindex.If theVonMises Stressexceedstheyieldstress,thematerialisconsidered tobeatthefailurecondition.

DYNAMICANALYSISOFCRANKSHAFT
y Themainobjectiveofthisstudywastheoptimizationoftheforgedsteel y

crankshaftwhichrequiresaccuratemagnitudeoftheloadingonthe componentthatconsistsofbendingandtorsion. Figureshowsthevariationoftheforceatthejournalbearingbetween crankshaftandconnectingroddefined.Ascanbeseeninthisfigure,the maximumloadinghappensattheangleof355 wherethecombustion takesplace. Asthedynamicloadingonthecomponentisafunctionofenginespeed, thesameanalysiswasperformedfordifferentenginespeedswhichwere intherangeofoperatingspeedforthisengine(i.e.2000rpmwhichisthe minimumenginespeedand2800rpm). Thereasonforthissituationcouldbeexplainedasfollows.Asmentioned previously,therearetwoloadsourcesintheengine;combustionand inertiaload. Itwaspointedoutthatthemaximumpressureinthecylinderdoesnot changeastheenginespeedchanges,thereforetheloadappliedtothe crankshaftatthemomentofmaximumpressureduetocombustiondoes notchange.

y Thisisabendingloadsinceitpassesthoughtthecenterofthecrank y

y y

radius.Ontheotherhand,theloadcausedbyinertiavariesasafunctionof enginespeed. Astheenginespeedincreasesthisforceincreasestoo.Theloadproduced bycombustionisgreaterthantheloadcausedbyinertiaandisinthe oppositedirection,whichmeansthesumofthesetwoforcesresultsinthe bendingforceatthetimeofcombustion. Soastheenginespeedincreasesthemagnitudeoftheinertiaforce increasesandthisamountisdeductedfromthegreaterforcewhichis causedbycombustion,resultinginadecreaseintotalloadmagnitude. However,factorssuchaswearandlubricationareimportantathigher enginespeeds. H Hence the th analysis l i for f speed dof f2000rpmis i sufficient ffi i tto t find fi dout tthe th fatiguenatureofcrankshaft. Furtherdiscussionoftheseissuesisavoidedsincetheyarenotofconcern inthisstudyandfatiguefailureisthemainfocus.Inthisspecificengine withitsdynamicloading.Thetorsional loadhasnoeffectontherangeof vonMises stressatthecriticallocation. Themainreasonfortorsional loadnothavingmucheffectonthestress g isthatthemaximumsofbending gandtorsional loading ghappen pp at range differenttimesduringtheenginecycle.Inaddition,whenthemainpeakof thebendingtakesplacethemagnitudeoftorsional

variationofforceovercrankshaftangle g ata speedof2000rpm

Loadof22.72mpaandboun.cond.

Def.+undef.shapeoforiginalmodel

Disp.vectorsumoforiginalmodel

Vonmises strainoforiginalmodel

Vonmises stressoforiginalmodel

Ycomp.ofdisp.Oforiginalmodel

Def+undef.shapeofoptimizedmodel p p

Vonmises stressofoptimizedmodel

Vonmises strainofoptimizedmodel

Ycomp.ofdisp.ofoptimizedmodel

RESULTSANDDISCUSSIONS
THEORITICALCALCULATIONS y ThetheoreticalworkingstressesoftheCrankshaftarecalculatedbyusingthe formula: y MaximumAllowableStress= UltimateTensileStrength/factorofSafety. y Thefactorofsafetyforthismodelisintherangeof46. y TheUltimateTensileStrengthforMediumCarbonSteelisgenerallytakenas 687n/mm2. y Fromtheanalysisitwasobservedthatmax.stressoccursat2000rpmsince maxloadingoccursatthatrpm.Hencethestressesduetootherloadingsare neglected. neglected y Therefore,byapplyingtheaboveformulaforthetwomodelsofcrankshaft,the theoreticalcalculationisdoneinthefollowingmanner. y Originalmodel: Maximumallowablestress=687/4=171.7N/mm^2. y Optimizedmodel: Maximumallowablestress=687/5=137.4N/mm^2

UNOPTIMIZEDMODEL y TheDeformedandUndeformedcontourshapeoftheunoptimizedmodel hasbeenplotted y Fromfigure,themaximumvalueofVonMises stressis104.261N/mm2 and theminimumvalueis11.85N/mm2.Themaximumstressisobtainedat thepointofapplicationoftheload. y ThemaximumvalueofVonMises Strainis.938e10andtheminimum valueis.595e04 y ThemaximumvalueoftheYcomponentofdisplacementofthe unoptimized modelis.511e3mm.Theminimumvaluewillbe.01191mm.
V mises Von i stress(N/mm^2) (N/ ^ ) 11.85 34.756 57.927 81 098 81.098 104.269 V mises Von i strain i .0595e3 .178e3 .297e3 .416e 416 3 .535e3

OPTIMIZEDMODEL TheDeformedandUndeformedcontourshapeoftheoptimizedmodelhasbeen plotted Fromfigure,themaximumvalueofVonMises is116.497N/mm2 andthe minimumvalueis12.94N/mm2.Themaximumstressisobtainedatthepointof application oftheload. ThemaximumvalueofVonMises Strainis.597e3andtheminimumvalueis 682e9 ThemaximumvalueoftheYcomponentofdisplacementoftheoptimizedmodel is595e3.Theminimumvaluewillbe.013mm
Vonmises stress(N/mm^2) 12.94 38 83 38.83 64.72 90 60 90.60 116.49 Vonmises strain .664e4 .199e3 .332e3 .464e 464 3 .597e3

CONCLUSION
y Thefollowingconclusionscanbedrawnfromtheanalysis: y Dynamicloadinganalysisofthecrankshaftresultsinmorerealistic

stresseswhereasstaticanalysisprovidesoverestimatedresults. results Accurate stressesarecriticalinputtofatigueanalysisandoptimizationofthe crankshaft. y Consideringtorsional loadintheoveralldynamicloadingconditionshasno effectonvonMises stressatthecriticallystressedlocation.Theeffectof torsiononthestressrangeisalsorelativelysmallatotherlocations undergoing g gtorsional load.Therefore, ,thecrankshaftanalysis y couldbe simplifiedtoapplyingonlybendingload. y Critical(i.e.failure)locationsonthecrankshaftgeometryarealllocatedon thefilletareasbecauseofhigh g stressgradients g intheselocations, ,which resultinhighstressconcentrationfactors. y Geometryoptimizationresultedin18%weightreductionoftheforged steelcrankshaft, ,whichwasachievedby ychanging g gthedimensionsand geometryofthecrankwebswhilemaintainingdynamicbalanceofthe crankshaft.